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1 and ASME V
Prerequisites: Completion of ASNT SNT-TC-1A recommended training for UT Level I & II qualification; i.e., 80 hours. Some angle beam experience preferred. Course Duration: The course is offered in 1-5 day blocks. Generally speaking, a person with limited angle beam experience will take longer to complete the curriculum; i.e., calibrate, detect, plot and record, interpret and evaluate all recordable indications. K2 Technologies will maintain records of attendance and examination documents for each student. A certificate of completion will be issued for successful detection; dimensioning and recording of a minimum of ten weld discontinuities. Course Description: This course is designed to provide the operator with an understanding of interpreting signals and characterizing flaws with angle beam ultrasonic examination in accordance to the AWS D1.1 and the ASME V codes. Course Objective: Upon completion of the course the participant will be able to: 1. Reference appropriate sections of both codes. 2. Interpret ultrasonic signals and characterize various indications related to welds. 3. Calibrate the ultrasonic instrument in accordance with the codes. 4. Interpret; Evaluate and Record weld discontinuities in accordance with the codes. 5. Gain confidence and efficiency in performing ultrasonic weld inspection. 6. Examine several test pieces of various geometries and successfully detect, dimension and record a minimum of ten weld discontinuities. 7. Pass a written examination specific to the aforementioned codes. Course Outline: 1. A General section that discusses ultrasonic weld testing, flaw sizing and characterization of weld flaws. 2. An AWS D1.1 section that covers specific calibration and examination techniques to this code. 3. An ASME V section that covers specific calibration and examination techniques to this code. Course material and test samples provided. Equipment Arrangements are available. Course Prepared by:
Ken L. Heaps 3400 Glenn Don Cr Anchorage AK 99504 907-333-1666 kheaps@k2technde.com
ASNT NDT III UT/MT/PT/LT/RT AWS CWI; API 570; 653 NACE See attached files UT Angle Beam #1 - #5
Near Field: .................................................................................................................................. 2 Beam Spread ............................................................................................................................... 2 Circumferential Scanning Formula............................................................................................. 2 dB equation ................................................................................................................................. 3 Wavelength: ................................................................................................................................ 3 Areas: .......................................................................................................................................... 3 Using a calculator: ...................................................................................................................... 3
Velocity Chart:............................................................................................................................................... 3 General Discussion of Ultrasonic Sizing of Flaws ........................................................................................ 5 Interpreting Signals ....................................................................................................................................... 6
Rise and Fall Time ...................................................................................................................... 6 Peaks ........................................................................................................................................... 6 Signal Base.................................................................................................................................. 7 Tip Diffracted.............................................................................................................................. 8 Transmit Receive ........................................................................................................................ 8
Characterizing Indications in Welds.............................................................................................................. 8
Root Indications (surface connected).......................................................................................... 8 Midwall Indications (subsurface) ............................................................................................. 11 Weld Cap Indications (surface connected) ............................................................................... 11
Interpretation Tips for Non-relevant and False Indications ......................................................................... 12
Refracted L-wave Indications ................................................................................................... 12 Creeper Wave Indications......................................................................................................... 12 Standing Wave Indications ....................................................................................................... 12
Pre Inspection Requirements...................................................................................................................... 13
Physical Measurements............................................................................................................. 13 Calculate Distances................................................................................................................... 13 Mark Surface Distances on Plate Adjacent to Weld................................................................. 13 Weld Profile/Sound Path Transparency.................................................................................... 13
Basic Angle Beam Calibration .................................................................................................................... 14
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Math Review
Trigonometry SP = T/cos0: 1st leg Sound Path SP = 2 x (T/cos0): Full V Sound Path SD = SP x sin0: Surface Distance T = SP x cos0: 1st Leg Depth T = 2 x (T [SP x cos0]): 2nd Leg Depth T = (SP x cos0) (2 x T): 3rd Leg Depth
SD Full V
T
SP 3rd leg
Near Field:
2 N= D x F (4 x V) Keep velocity in microseconds to cancel out frequency exponents. Near field calculations are important when dimensioning flaws because they can mask tip diffraction signals.
Beam Spread SIN0 = 1.22 ( / D) The sin value for angle beam spread equals 1.22 x wavelength divided by diameter. Its a sin value so you need to do a sin-1 function to convert it back into a degree value. Beam spread plots may be required and they should always be supported by a Near Field and Beam Spread calculations. The 1.22 constant plots the theoretical beam edge. 1.09 constant for 12 dB. Circumferential Scanning Formula SIN01 = (ID/OD) x SIN02
Angle Beam General K2 Technologies Rev 1 05/01/04
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= V/F
Keep velocity in microseconds to cancel out frequency exponents. Flaws can be reliably detected only when greater than wavelength. Areas: Area of circle = pi x radius2 Area of rectangle = length x height Using a calculator: Make sure calculator is set to Degrees, NOT Radians & NOT Gradients. Degree units used in formulas are sin values. To convert sin value back to degree uses the sin-1 of the sin value. Velocity Chart:
Material Longitudinal Velocity Shear Velocity Acoustic Impedance
Air Aluminum Alumina Oxide Beryllium Boron Carbide Brass Cadmium Copper Glass (crown) Glycerin Gold Ice Inconel
0.013 0.25 0.39 0.51 0.43 0.17 0.11 0.18 0.21 0.075 0.13 0.16 0.22
0.33 6.3 9.9 12.9 11 4.3 2.8 4.7 5.3 1.9 3.2 4 5.7
0.12 0.23 0.35 0.08 0.059 0.089 0.12 0.047 0.08 0.12
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The ASME Section V, Articles 4 and 5 and AWS D1.1 Annex K codes require flaw dimensioning using decibel (dB) drop sizing methods; e.g., a 50% amplitude drop. It has been demonstrated that when the flaw is 50% drop 50% drop 50% drop 50% drop less than the beam spread, the dB drop sizing method tends to dimension the beam profile instead of the actual flaw size, thereby over sizing the flaw. This becomes even more pronounced Flaws when plotting flaws using an angle beam; often the flaws plot into the base metal when they shouldnt, or they dont plot to the exact same position from each side of the weld when they should. The Flaw dimension Element dimension diagram on the right shows the transducer dimensioning the flaws via the 50% amplitude drop. The flaw on the left gets oversized because its smaller than the beam profile. The flaw on the left is accurately sized because its Figure 3. Flaw Dimensioning, 6dB Drop Method dimension is larger than the beam profile. In addition, it is recognized that other techniques different than the nominal 45o, 60o & 70o shear wave examinations may be required verify and dimension planar flaws. This is a good reason why codes specify a scanning sensitivity that is above the reference level. Flaw
Angle Beam General K2 Technologies Rev 1 05/01/04
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Interpreting Signals
Rise and Fall Time The signal rise time is related to how fast the signal peaks as the transducer is moved toward a reflector, and how fast it falls when the transducer is moved away from it. As shown below, the rise and fall time of signals is drastically affected by the angle of the sound beam.
70o 60o 45o
In the above diagram the beam profile is dimensioned instead of the SDH. This can lead to over sizing flaws as well as underestimating flaw depth. This problem alleviates itself once the flaw size is equal to or larger then the beam profile. Discontinuities with a through wall dimension greater than the beam profile dimension will have a longer rise/fall time and be more accurately dimensioned. Geometry indications from a weld cap or weld root exhibit a slow rise/fall time and have a broad base signal with multiple peaks. Peaks Sound that is reflected back to the transducer at different or varying time of flight (TOF) indicates a multifaceted reflector surface and creates multiple peaks on the signal. In most cases the multifaceted surface is also irregular to
Angle Beam General K2 Technologies Rev 1 05/01/04
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Of the nominal angles, the 70o shear wave mode is nearest to normal incidence to a subsurface vertical weld centerline crack and will return the most energy.
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Tip Diffracted The radial wave pattern that emanates from a long crack tip is reliably detectable only in the far field and requires a good signal to noise ratio. Better results obtained with a highly damped 45o or 60o shear wave. Interpretation of RF A-scan display better for low amplitude signals. .
These signals are important, due to their vertical orientation these types of planar indications are difficult to detect. The technician needs to acknowledge their critical nature and further investigate with other angles. Transmit Receive This signal only appears when it reflects from a planar flaw and is received on a second transducer. A transmit/receive technique can be employed to further investigate a planar discontinuity. Through transmission is an amplitude attenuation test.
The operator should determine if the weld exhibits a root geometry that will reflect sound back to the transducer. The sound path should calculate to a thickness equal to or slightly greater than weld plate thickness. The surface distance from each side of the weld should not plot exactly to the same point or to the weld centerline. This signal should be closely interpreted during inspection, so that other root indications coming up just in front of, or on the front flank of this signal, may be noted and interpreted also.
Angle Beam General K2 Technologies Rev 1 05/01/04
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2. Excessive Root:
Excessive Root is similar to the Root Geometry noted in Figure 9 above. Excessive root bead will have sharper sides due to excess weld metal melting through. Signals will vary more in amplitude and exhibit a greater TOF than normal root geometry.
3. Longitudinal Crack (weld metal or HAZ):
Best detected with a 45o angle due to corner trap at ID. Signal will appear sharp with fast rise time. The 60o angle will provide approximately the return amplitude of the 45o angle. If the crack follows grain boundaries and exhibits a multifaceted face the signal may exhibit a multiple peak and return less sound than a notch in a reference block. Crack indications should plot to same point from each side of weld.
SD plots to same point above crack
Transducer needs to be aligned parallel to weld direction and skewed 30o to propagate sound in towards the weld root to detect short transverse root cracks. The skewed sound beam will cause some sound to reflect off small transverse cracks and away from transducer, reducing the returned amplitude.
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Weld Cap Figure 11. Rotation of transducer for detection of transverse flaws.
Lack of fusion connected to ID at root face is difficult to distinguish from a longitudinal root crack. If the depth of the LOF exceeds the root land and follows the angle of the bevel it will return less sound from the side that is not at normal incidence to the sound beam.
6. Incomplete Penetration (IP):
A tight root fit up during welding, or poor arc penetration, can make this indication difficult to distinguish from a centerline root crack. Signal characteristics from IP should exhibit a single peak because the sound beam is reflecting from a uniform surface.
Surface distance will not plot to exact same point. Depth will be equal to or less than plate thickness.
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The sound beam needs to strike lack of fusion at or near normal incidence, therefore lack of fusion exhibits greater amplitude on the 2nd leg when scanning from same side of weld as indication, or 1st leg when on opposite side of weld; unless weld thickness is great enough the weld cap usually creates an obstacle and the 3rd leg is required when on the opposite side of the weld joint. A 60o angle is best suited for LOF on a 30o weld joint bevel and a 70o angle is best suited for LOF on a 22.5o weld joint bevel because they are nearest the normal incidence of 90o.
Second leg on opposite side of weld reflects off LOF
A slag line can generally be detected from both sides of the weld. Signal characteristics may include multiple peaks and a broad base.
2. Porosity
Porosity is generally difficult to detect. Signal characteristics may include multiple peaks. Peaks can be maintained while skewing transducer. 3. Crack (weld metal or HAZ) The midwall crack is one of the most difficult indications to detect. Generally speaking, a vertical orientation of a planar flaw is best detected with a 70o angle. See Figures 7 & 8 for alternative techniques for characterizing a midwall crack. Weld Cap Indications (surface connected)
1. Weld Cap Geometry
The operator should determine if the weld exhibits a weld cap geometry that will reflect sound back to the transducer. This is a broad based signal with multiple peaks and is generally maintained over full length of weld. Adjust amplitude to reference level and try dampening signal with finger. The sound path should calculate to a full V path or slightly greater. The surface distance should plot to the opposite side of weld cap. This signal should be closely interpreted during examination, so that other indications coming up just in front of, or on the front flank of this signal, may be noted and interpreted also.
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Longitudinal Cracks are best detected at the end of the 2nd leg of the 45o angle. Shallow toe cracks are easy to miss when weld cap geometry exists. 3. Transverse Cracks (weld metal or HAZ) Transducer needs to be aligned parallel to weld direction. The end of the second leg of a 45o angle is best suited for this indication.
Standing Wave Indications More sound reflects inside a 70o wedge than a 60o or 45o wedge, making the 70o vulnerable to this indication. When couplant builds up on the front of the wedge a mid screen standing signal with a large signal base may appear on the CRT display. This signal is created by the reflected and refracted sound inside the wedge and stays at the same TOF on the baseline. Wiping the excess couplant off the end of the wedge will eliminate this false indication.
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1"
2"
1 "
4"
1"
4"
1"
3"
1"
5"
In the above diagrams the dashed sound path is not at an angle that can be received from the transducer element, only the solid sound path lines are at the correct angle to create a signal. The distance between signals is equal to the sum of both radiuses.
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6. If doing an ASME weld examination on an in-service pressure vessel dimensioning indications for evaluation to acceptance standards to ASME VIII App 12.1 which Article would apply?
7. If performing an ASME 24 schedule 40 pipe weld examination, which article would apply? 8. Which code allows the use of dual transducers?
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9. Which code requires a horizontal linearity procedure? 10. Which Article(s) require Amplitude Control and Screen Height Linearities? 11. What ASME Article section describes the beam spread measurement? 12. What is the best transducer selection for an AWS job? a. .25 diameter, 5MHz b. .50 diameter, 2.25 MHz c. 1 diameter 2.5 MHz d. b & c above 13. When examining a 3 butt weld on a building to AWS which of the following is correct a. A 45o and 60o angle are required b. A 60o angle to the middle half and 45o angle for the bottom quarter c. A 70o, with the weld cap ground flush d. A 45o and 70o e. c & d above 14. In question 13, the following information has been tabulated: reference level 28, indication level 40, examination angle 70o and reflector at 8 sound path. What is the indication rating? a. A b. B c. C d. D 15. The indication for question 13 is 2.25 inches in length, is it a. Acceptable b. Rejectable 16. What is the scanning sensitivity for question 13? a. 20 b. 25 c. 19 d. none of the above
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17. What frequency is most appropriate for an AWS examination? a. 7.5 MHz b. 10.0 MHz c. 5 MHz d. 2.5Mhz 18. When calibrating to AWS, what is the diameter of the sensitivity reflector in the IIW block? a. .60 b. .060 mm c. 60 mm d. .060 19. What is the transducer position(s) (its a letter) for verifying a wedge angle on an IIW block? a. A b. K c. C d. F e. B 20. What part of AWS would you reference to develop a technique for a material < 5/16?
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